Optimal Rotor Design of an 150 kW-Class IPMSM by the 3-D Voltage–Inductance-Map Analysis Method

A method is presented to determine the detailed design of a 150 kW-class interior permanent-magnet synchronous motor. The basic designs of stator and rotor were determined, after dividing the designed models into the best and worst cases on the basis of the rotor-shaped parameters. First, the three-bridge basic model satisfying the structural (mechanical) safety factor of the rotor is proposed. The three-bridge basic model does not meet the required torque at rated and maximum speed compared to the no-bridge model. Therefore, it is necessary to perform the design analysis through the selection of various design parameters. However, it is hard and takes alot of time to perform an analysis with numerous shape parameters. Therefore, design parameters with the greatest effect on torque and induced voltage are found using the sensitivity analysis. And the 3-D voltage–inductance map parameters were analyzed. Then, the design of the final model was predicted. On the basis of this prediction, the final model was extracted with a trend analysis. Finally, the final model was validated with experiments.